ETI Chrysler LLC General Discussion

1. ETIChrysler LLCGeneral Discussion Doug Craig June 18, 2008

2. Headlines… • Summer 2007 – DaimlerChrysler sells off majority portion of the Chrysler group. Cerberus Capital Management now owns 80.1% with Daimler AG retaining 19.9% • The German team became Daimler AG and the US team became Chrysler LLC • Some collaboration and component sharing will remain in place • Significant headcount reductions and financial programs implemented to improve profitability at Chrysler LLC – more coming soon • Still enjoying day-to-day evolution of the private capital ownership

3. Chrysler LLC New Vehicles • New Crossover Vehicle • Fall 2007 Launched the Journey – designation JC49 – based off of JS platform • New HEMI vehicle • Spring 2008 – Launched the Challenger SRT-8 – designation LC23 – based off of LX platform • Summer 2008 – Launching Challenger non SRT versions • New Ram truck • Summer 2008 Launching new Ram 1500 trucks – designation DS • New Hybrids • Summer 2008 – Launching Hybrid Durango & Hybrid Aspen

4. NEW Chrysler Material Identification • For BIW blow-ups released by service • Three “repairability grades” of steel • LS – “Low-Strength” steel • less than 270 MPa tensile strength • basically “mild steel” • HS – “High-Strength” steel • 270 MPa to 600 MPa tensile strength • Covers range of “HSS”, “HSLA”, and most “AHSS” • VHS – “Very High-Strength” steel • greater than 600 MPa tensile strength • covers upper end of “AHSS” and all “UHHS”

5. NEW Chrysler Material Identification Continued • LS • High likelihood of being repairable • Good weldability • STRSW • Weld bonding • MIG • MIG Braze for exterior cosmetic panels • Least sensitive to heat

6. NEW Chrysler Material Identification Continued • HS • Reduced degree of repairability • Good weldability • STRSW • Weld bonding • MIG • Increased sensitivity to heat

7. NEW Chrysler Material Identification Continued • VHS • Very limited to no repairability • Limited weldability • STRSW • Weld bonding (possibly) • MIG (possibly) • Very sensitivity to heat • Must replace at OE location using OE weld methodology • This material “range” includes the H/S borons

8. NEW Chrysler Material Identification Continued • ..\..\WM6.1\Collision Repair Standards\09 DS Beta Test\DPM003095958 2009DS Regular Cab Exploded View 061708.pdf

9. Possible Excessive Tire Wear?

10. Chrysler Hybrid Introduction

11. Chrysler Hybrid Introduction The Chrysler Aspen hybrid and Dodge Durango hybrid vehicles, which will be introduced in the 2009 model year, are gasoline-electric vehicles. • The basic features of the vehicles are the same as the traditional models. • The hybrids use a conventional internal combustion engine along with a high voltage transmission with integrated electrical motors for propulsion. • The internal combustion engine and fuel system operate in the same manner as traditional Aspen and Durango models. • The 12 volt system operates similar to a standard 12-volt system, it just does not include an alternator.

12. Chrysler Hybrid Introduction Main HEV Components The main components found on the HEV are: • High Voltage wiring (HV) • Traction Power Inverter Module (TPIM)/Accessory Power Module (APM) • Electric A/C Compressor (EAC) Transmission • Electrically Variable (EV) Transmission • High Voltage Battery Pack (300V)

13. Chrysler Hybrid Safety • General Hybrid Safety • Always assume that there is voltage present. • Do not attempt to work on the vehicle until the proper electrical training requirements have been met. • Apply the One Hand Rule, whenever feasible, while working on potentially energized power systems to minimize potential hazards. • Establish a perimeter around the vehicle, as a boundary, and post non-metallic signs which high voltage electrical work is being preformed. • Always wear personal protective equipment (PPE). • Never work alone; a second person with PPE should be there as well. • Identify high voltage sources (labels or orange convoluted tubing). • Disconnect power sources.

14. Chrysler Hybrid Safety • Protective Safety Gear for HEV work: • PPE: • Rubber-soled shoes • Cotton Clothing (Non-synthetic) • Safety Glasses with side shields. • Isolation Gloves with leather inserts • Class ‘0’ isolation gloves rated @ 1000 volts. • One Pair (yours) of High Voltage Gloves with Leather Protectors (1000 VAC minimum rating) (Class 0) • Second Pair (rescue) of High Voltage Gloves with Leather Protectors (1000 VAC minimum rating) (Class 0)

15. Chrysler Hybrid Safety • Remove Metal Objects • Examples of metal objects to remove when working on Hybrid Electrical Vehicles (HEV) include: • Rings • Watches • Necklaces • Belt Buckles • Don’t lean on vehicle if wearing pants with a metal zipper

16. Chrysler Hybrid Identification • Distinguishing Characteristics With the exception of the high voltage electrical system, the Aspen and Durango hybrid vehicles are similar in design to the traditional models. Distinguishing characteristics that may help to identify a hybrid model include: • “Hybrid” badge located on the Fenders of the vehicle and on the Lift Gate. • “Hybrid” logo molded into the air cleaner cover. • Unique instrument cluster with hybrid power gauge.

17. Chrysler Hybrid Identification • Collisions can damage or destroy hybrid vehicle labels/badges making identification difficult to determine. In such cases it may be necessary for rescue personnel to visually inspect for the presence of high voltage system parts. • High voltage parts are marked with a high voltage warning label. • All high voltage wiring on the Aspen and Durango hybrids are colored bright orange. • Hybrid Identification Using the VIN ~ The vehicle identification number (VIN) may be used to determine if the vehicle is a hybrid. A number one “1” in the sixth (6th) position of the VIN indicates that a Chrysler vehicle is a hybrid.

18. High Voltage Hybrid System • Operation ~ Hybrid models use: • An internal combustion engine • A high voltage battery pack • A transmission with integrated electric motors to power and propel the vehicle. • The Aspen and Durango hybrids are full hybrid vehicles, making them capable of electric-only propulsion. • The vehicles are powered at low speeds and in reverse by the high voltage battery pack. • The internal combustion engine powers the vehicle at normal driving speeds. • The internal combustion engine and the high voltage battery pack will power the vehicle during hard acceleration. • The internal combustion engine is also used to recharge the high voltage battery. • When the vehicle is stopped, the internal combustion engine and the transmission with integrated electrical motors may shut down, while the rest of the hybrid system remains operational.

19. High Voltage Hybrid System • The high voltage system consists of the following components: • High voltage battery • High voltage cables (there are multiple sets of cables) • Traction power inverter module (TPIM)/accessory power module (APM) • Transmission with integrated electric motors • Electrical air conditioning compressor (EAC) • The high voltage battery is connected to the TPIM via high voltage cables that are orange in color. The TPIM also includes the high voltage-to-12-volt power converter (APM) and connects to high voltage direct current (DC) to the EAC, and high voltage alternating current (AC) to the transmission, also via bright orange colored cables. The EAC also has a high voltage connector that is orange colored.

20. High Voltage Hybrid Components

21. High Voltage Hybrid Components

22. High Voltage Hybrid Components • Safety Features ~ In most accident situations an automatic shut-off of the high voltage system is triggered and the flow of energy from the high voltage system is disabled. • During this process the TPIM stops the high voltage generation in the transmission with integrated electric motors, commands the high voltage battery to open the main contactors, and begins discharging the high voltage capacitor in order to de-energize the high voltage system completely within five (5) seconds. • If the accident does not trigger an automatic shut-off of the high voltage system, de-energizing the high voltage system could take up to five (5) minutes.

23. High Voltage Hybrid System • High Voltage Components of HEV: • All high voltage wires/harness are marked with orange insulation. • The high voltage system is separate from the 12 volt wiring system.

24. High Voltage Hybrid System • High Voltage Battery Pack • Battery is located under rear seat. • Battery is Nickel Metal Hydride from Panasonic • Alkali is very hazardous to eyes if battery leaks. • May cause corneal damage and loss of eye sight; flush 15 minutes with water and consult a doctor. • Vinegar is a neutralizing agent and should be available along with sand and a Class ABC fire extinguisher. • If battery temperature rises due to over charging or discharging, hydrogen gases may be released. • Do Not spray battery pack with water since this may cause a short circuit. • Do Not wipe modules with a dry cloth since static electricity may be an ignition source.

25. Chrysler Hybrid Training Requirements Chrysler Hybrid Training Requirements  Prerequisites Master Certified Powertrain/level 4 in 2, 6 and 8 Master Certified Electrical/level 4 in 6 and 7 WEB High Voltage Safety - Self Study at Level 1  How to disable and enable high voltage system safely. Hybrid Propulsion and Systems Integration - Self Study CD What it takes to convert Aspen/Durango into a Hybrid Overview of effected systems to prepare for ILT Class Hybrid Electric Vehicle Instructor Led Course How to diagnose high voltage systems. Hybrid Electric Vehicle - follow-up and testing CD